Dual Scanner Inspection for Bladed Rotor Point Cloud Density
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Solution Overview
Problem
Existing inspection systems for integrally bladed rotors (IBRs) in gas turbine engines lack the capability to efficiently scan and generate high-resolution point clouds of the entire rotor surface, leading to incomplete or low-fidelity inspections.
Innovation Solution
The proposed inspection system employs two blue light scanners moveably coupled to a support structure, along with a motor and controller system, to scan the bladed rotor from multiple angles, generating a high-density point cloud that covers nearly 100% of the rotor's external surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single scanner is used to inspect the bladed rotor, then the device complexity is reduced, but the point cloud density and inspection completeness deteriorate
Solution Approach 1:
The inspection system is segmented into multiple independent scanner units (first scanner and second scanner) that can operate simultaneously on different portions of the rotor. Each scanner is a complete functional unit with its own controller, allowing independent operation while contributing to the overall point cloud data set, thereby achieving higher density without requiring a single complex monolithic system
Solution Approach 2:
The patent merges the output data from multiple scanners into a unified point cloud representation of the rotor. The controllers integrate scan data from both scanners and the motor positioning system to generate a comprehensive 3D model, combining the capabilities of simpler individual units to achieve the functionality of a more complex single system
2Device complexity
If a single scanner inspects the bladed rotor, then the device complexity is reduced, but the inspection time and productivity deteriorate
Solution Approach 1:
The inspection task is divided into concurrent operations by multiple scanners that can inspect different portions of the rotor simultaneously. The first scanner and second scanner operate in parallel, each responsible for specific angular sectors of the rotor, effectively halving the inspection time compared to a single scanner while maintaining comparable system architecture
Solution Approach 2:
The motor continuously rotates the rotor at constant speed while both scanners continuously capture data without interruption. This continuous operation eliminates idle time between scanning operations, ensuring that the rotor surface is inspected without gaps or delays, thereby maximizing productivity through sustained useful action
3Device complexity
If a single scanner is used, then the device complexity is reduced, but the coverage of external surface area deteriorates
Solution Approach 1:
The rotor surface is divided into multiple angular sectors that are inspected by different scanners simultaneously. The first scanner covers a first angular range while the second scanner covers a second angular range, ensuring complete surface coverage through partitioning of the inspection task across multiple simpler units
Solution Approach 2:
The patent adds the temporal dimension to the spatial coverage by having scanners operate at different angular positions simultaneously. As the rotor rotates, scanners at different angular locations capture data from different surface regions, effectively mapping the entire 3D surface through coordinated spatial and temporal sampling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system achieves a point density twice that of single scanner systems, ensuring comprehensive and high-fidelity scans of the bladed rotor, which is critical for accurate inspection and potential repair analysis.
Implementation Method 1
both blue light scanners
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An inspection system (300) for a bladed rotor is disclosed herein. In various embodiments, the inspection system (300) comprises: a support structure (302); a first scanner (310) moveably coupled to the support structure (302); a second scanner (610) moveably coupled to the support structure (302); a motor (404) operably coupled to a shaft (308), the shaft (308) rotatably coupled to the support structure (302), the shaft (308) configured to be coupled to the bladed rotor (100); and a controller (301) in electronic communication with the first scanner (310), the second scanner (610), and the motor (404), the controller (301) configured to: command the first scanner (310) to scan the bladed rotor (100); command the second scanner (610) to scan the bladed rotor (100); and generate a point cloud for the bladed rotor (100) based on scanning data received from the first scanner (310) and the second scanner (610).